Flat Solar Cell Stack Structure via Intermediary Electrode Line

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Solution Overview

Problem

The existing connection methods between solar cells and wire members in solar cell stack structures often result in a step or gap, leading to potential disconnection and separation issues when the structure is mounted in vehicles, such as hybrid or electric vehicles, due to the mismatched shapes of the round wire members and plane-shaped solar cell elements.

Innovation Solution

A solar cell stack structure is designed with an electrode formed on the surface of the solar cell, where the electrode is in contact with an electrode line coated on the substrate, allowing the electrode line to protrude and connect with the wire member without generating a step, using conductive pastes like silver, aluminum, or copper, and a ceramic line for improved adhesion and visibility, ensuring a flat connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a round wire member is directly connected to a plane-shaped solar cell element, then the connection is simple, but a step or gap is generated in the stack structure

Engineering Contradiction:

Improveconnection structureVSAvoidflatness of stack structure

Core Design Contradiction:

Device complexityVSShape

Solution Approach 1:

The patent introduces an electrode line as an intermediary component between the round wire member and the plane-shaped solar cell. The electrode line is coated on the substrate surface and makes contact with the electrode of the solar cell, serving as a mediator that eliminates the step or gap that would otherwise be created by directly connecting the round wire to the flat solar cell surface.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If a wire member is mounted in a vehicle with a step structure, then the connection is straightforward, but disconnection or separation occurs due to vehicle movement

Engineering Contradiction:

Improvemounting processVSAvoidconnection stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Instead of mounting the wire directly to create a step structure, the patent inverts the approach by coating the electrode line on the substrate surface first, then making it contact with the solar cell electrode. This reverses the traditional mounting sequence and eliminates the step structure that causes disconnection during vehicle movement.

Inventive Principle:

Principle #13The other way round (Inversion)

3Shape

If an electrode line is coated on the substrate to connect the electrode and wire member, then no step is generated, but the connection structure becomes more complex

Engineering Contradiction:

Improveflatness of stack structureVSAvoidconnection structure

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent merges the electrode line function with the substrate surface by coating the electrode line directly on the substrate. This combining of functions (substrate + electrode line) simplifies the overall structure despite adding the electrode line layer, as it eliminates the need for separate mounting structures and reduces the number of discrete components.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3220423B1Solar cell stack structure having no gap between solar cell and substrate

Publication Date: 2022.10.26 HYUNDAI MOTOR CO LTD

Figure 1(a)~2
Figure 3~4
Figure 5(a)~5(b)

AI summary

A solar cell in a stack structure having no step may include a solar cell, and an electrode formed on one surface of the solar cell, in which the solar cell is/are stacked on a center portion of a substrate with the electrode interposed therebetween, and the electrode is/are in contact with an electrode line coated on an edge portion of the substrate.